SAMPE Brazil Conference 2012

November 6, 2012

From Carbon Fiber

to

Carbon Fiber Reinforced ThermoPlastics

Mr. Joe Spangler – Technical Services Manager – Toho Tenax America Dr. Anatole Gilliot - Aerospace Marketing Toho Tenax Europe

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 2

Content

• Carbon fiber with P-sizing

• Thermoplastics vs. Thermosets

• CFRTP Product Families

• TPUD High TS & IM Fiber(s) (Standard & Intermediate Modulus)

• Thermoplastic Part Making with TPUD

• TPCL PEEK-High TS Fiber (Standard Modulus)

• Thermoplastic Part Making with TPCL

• Conclusion

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 3

Carbon Fiber with P-sizing

• Current sizing cannot be used with most thermoplastics because they are processed at temperatures above the sizing thermal resistance (250°C).

– Sizing is either not applied or removed (pyrolysis, solvent) from the fiber

before impregnation with thermoplastic matrices.

• Toho Tenax developed the P-sizing which withstand temperature up to ~ 450°C without degradation.

– can be applied to all kinds of fiber, with the same fiber mechanical properties

– focus is on 3K, 12K, and 24K fibers, High TS and IM Fiber.

• P-sizing can be used with high temperature polymers (PEEK) but also low

temperature polymers (PA6) and high temperature thermosets (BMI).

• P-sizing can be processed for UD-prepreg, fabric or pultrusion.

Abrasion Abrasion with 200cN

High TS Fiber ref ref

High TS Fiber – P-sized -21% -98%

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 4

Thermoplastics vs. Thermosets

Intrinsic Properties

Thermoplastic Thermoset

- room temperature and long-term storage

(when protected from UV)

- low temperature storage (1-component resin system)

- room temperature storage (mixture of two or more components)

- no transport restriction - special conditions for transport (cold)

- not REACH critical - in some cases REACH critical (registration needed)

- high viscosity

(high pressure needed for impregnation)

- low viscosity

(easy impregnation of reinforcement)

- high melting temperature (>200°C) - low to medium curing temperature (<200°C, EP)

- short process time (several minutes) - long process time (several hours)

- several-ways use (melting & cooling/solidification) - one-way use (chemical reaction: curing)

- re-use / recycle possible (re-melting) - limited recycling (burn-off, grinding)

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 5

CFRTP Product Families

Pa

rt g

eo

me

try

co

mp

lex

ity

Short Fiber

Long-Fiber

ʺunlimitedʺ fiber length

Stretch-broken fiber

Co-mingled

Limited fiber length

Woven fabric

Unidirectional

Mechanical properties

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 6

CFRTP Product Families

Woven fabric

Unidirectional

Short Fibre

Lo

Pa

rt g

eo

me

try

co

mp

lex

ity

High TS Short Fiber

Long-Fiber

Stretch-broken fiber

Co-mingled High TS Fiber TPCL

High TS Fiber TPUD

Mechanical properties

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 7

Carbon Fiber ThermoPlastics

ThermoPlastic UniDirectional

(High TS & IM Fiber TPUD)

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 8

High TD Fiber TPUD

TPUD PEEK-High TS Fiber (Standard & IM Modulus)

• High TS or IM fiber with tailored sizing for thermoplastics applications.

• Width: 6.35 mm (¼”) to 304.8 mm (12”)

• European source (production in Oberbruch)

• Aero and non-aero grade

Fiber

Reinforcement

FAW

weight

[g/m2]

Fiber

Matrix

content

[%wt.]

Matrix

Nominal

thickness

[mm]

TPUD PEEK High TS – Standard Modulus

UD

145

High TS 12K with P-sizing

34

PEEK

0.136

TPUD PEEK – Intermediate Modulus Fiber

UD

145

Intermediate Modulus with P-sizing

34

PEEK

0.134

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2012 9

TPUD PART MAKING

Lay-up Consolidation

using heat & pressure

TPUD

Hand Lay-up + Local welding

(HLY)

Automated Tape Lay-up

(ATL)

Automated Fiber Placement

(AFP)

Vacuum bagging Autoclave

Oven

Static Press

(Semi)-Continuous

Press Forming (CPF)

Filament Winding

(FW)

Similar to Thermoset Prepreg Without debulking

(Time saving vs. TS)

5-30 min

(Consolidation time)

• Automated process (ATL, AFP) • Short cycle time

• Out of autoclave consolidation • TP joining technologies (resistance, ultrasonic, induction)

Carbon Fiber ThermoPlastics

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2011 10

High TS Fiber ThermoPlastic Consolidated Laminate (TPCL)

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2011 11

High TS TPCL (PEEK)

Materials

Tenax®-E

Reinforcement

FAW

weight

[g/m2]

Fiber

Matrix

content

[%wt.]

Matrix

Nominal thickness

[mm]

TPCL PEEK

5HS fabric

285

High TS 3K

40

PEEK

0.31

• Laminate size: 800 (warp) x 1200 mm (0.96 m2)

• Thickness: typically from 1.86 to 4.96 mm (6 to 16 plies)

• Aero grade

• Glass/PEEK: surface layer for corrosion protection

• Bronze mesh/PEEK: surface layer for lightning strike protection o Future development of nanotube l.s.p. fiber.

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2011 12

TPCL: Part making

TPCL Blanket

nesting/trimming

Heating Thermoforming

& Cooling

Trimming/

Drilling

IR-oven Press

< 60 min (dependent

on part shape and

laminate size)

< 5 min

< 5 min

Similar to Thermoset

• Automated process (pick and place) • Complex part shape

• Very short cycle time • Joining technologies

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2011 13

Conclusion

• Room temperature transportable and storable.

• High-performance mechanical properties.

• Good properties against fire, smoke and toxicity.

• Automated production.

• Short cycle time.

• Welding technologies.

• Opportunities for repair technique.

• Recyclable.

Mr. Joe Spangler & Dr. Anatole Gilliot 11.06.2011 14

Thanks for your attention

Tenax® ThermoPlastics